Why migrate your control system now?
Legacy Systems are hard to maintain…
• They have limited spare parts (and failures increase…)
• The run on old PC hardware and operating systems
• They provide limited communications and diagnostics
• And the people who know them are retiring!
A migration to a modern, sustainable control system will provide new tools to connect to new systems that provide benefits in addition to reliability and parts availability. Their open communications architecture allows for easier connectivity to Historians, Advanced Control, MES for PlantPAx.
This presentation covers the questions asked, migration strategies and risks, and steps that are needed for a control system migration. Two case studies with different approaches are described and the results summarized.
2. Presenters
• Dan Burger, P.E., C.E.M. – Business Development Market Manager
Having over 12 years of direct experience in the migration and modernization of various
control system platforms, including the planning, engineering, and cutover. He holds a P.E. in
Control Systems Engineering and is a Certified Energy Manager.
• James Riccardi, P.E. – Group Manager, California Projects
Over 24 years of automation experience including design, implementation, commissioning
and validation of various controls platforms across different industries. Jim has previously
worked with Air Products and Bailey Controls. He has led projects throughout the US and
Asia. He has been with RoviSys since 2000 and is currently based in Ventura, CA.
3. Given today's slow economic growth, reduced plant
engineering and maintenance staffing and tight
capital budget constraints, understanding how best
to propose, plan, execute and allocate limited
resources for successful process control system
migrations is imperative for manufacturers seeking to
maintain or increase productivity and efficiency.
Business Environment
5. Lobbying for Support
• You are the visionary, determine your approach
• Preach the specific benefits
• Ask peers for their input
• Build a plan and revise as needed
• Consult a partner
• Generate a FEED Study w/ cost estimate
6. Why migrate now?
• Legacy Systems are hard to maintain
• Limited Spare Parts (and failures increase…)
• Old PC hardware and Operating Systems
• Communications and diagnostics limitations
• People who know them are retiring
• New tools connect to new systems
• Legacy Systems are generally closed architecture
• Historians, Advanced Control, MES for Plant Pax
7. Payback $$
• Increasing cost of
• Spare Parts
• Trained Support (internal + external)
• Support Agreements
• Unplanned Downtime
• Improved visibility into operations
• More efficient operations
• New product/process/equipment
• Compliance
8. Migration Approach
1. Rip and Replace
2. Phased by system architecture
3. Phased by process area
4. With same system vendor / select new vendor
9. Project Definition
• Hands on System Audit
• High Level Migration Plan
• Savings/Payback
• FEL +/- 30% Estimate
• Authorization to Proceed?
• Bid Specs
• Select Vendors
• +/- 10% Estimates
• System procurement & Engineering
• Cutover
• Support
10. System Audit
• Eyes on Audit
• Hardware
• Code
• Interview
• Operations
• Maintenance
• Engineering
• Understand Goals and Challenges
11. Migration Plan
• High level design
• Rip & Replace or Phased Migration?
• Priorities
• HMI unsupportable
• Stock Prep can’t run
• New Coater on the way
• Who will drive?
• How to justify?
12. Front End Loading
• Audit drives FEL Estimates
• I/O counts
• HMI Requirements
• E&I Upgrades required?
• New network?
• Installation challenges
• System Architecture & BOM
• Schedule
• Resource Loading
Choose Approach Carefully!
13. Why Consider Phased Migration?
Rip & Replace Phased
Manpower Larger team Hit and run
Downtime Longer Outage Many Outages
Risk Higher Lower
Faith All in Focused Effort
Cash Flow One Year Gradual
Cost Most cost effective Higher overall cost
Payback Improvement NOW Time is money
14. Glass Plant Virtualized Plant PAx
End User - System Architecture
Manufacturing Zone
Site Manufacturing
Operations and Control
Level 3
Demiliterized Zone
(DMZ)
Enterprise Zone
Levels 4 and 5
Cell/Area Zone
Levels 0–2
Internet
FIBER
FIBER
FIBER
FIBER
FIBER
VLAN
VLAN
FIBER
FIBER
Enterprise Zone
Provided by End
User IT
HMI Server
(Primary) MES/Historian Server
Engineering
Workstation #1
HMI Server
(Secondary)
VLAN
FIBER
FIBER
Enterprise Zone
Office PC’s
VLAN
FT View SE HMI Clients (QTY 5):
`
`
`
VLAN
PanelView+ (Qty 5)
FIBER
Engineering
Workstation #2
VLAN
Terminal Server
(Primary)
VLAN
Terminal Server
(Secondary)
VLAN Domain Controller
(Primary)
VLAN
Domain Controller
(Secondary)
VLAN
NOTE: Maximum
allowed length of
Cat 6 cable is 100
meters (330ft)
VLAN
FT View SE HMI Clients (QTY 2):
`
`
`
VLAN
HIST01
ENG01
ENG02
TS01
TS02
DOM01
DOM02
Cisco 3750X
Switch Stack
DLR Representation
Is Symbolic
Only...See Area
Pages For Specifics
VLAN
Ctrl Area 3
Ctrl Area 3 Device Level
Ring
RIO – Area 3 2
VLAN
RIO – Area 3 1
VLAN
`
FT View SE HMI Client
HMI STRATIX
CLX – Area 3 0A CLX – Area 3 0B
DLR Representation
Is Symbolic
Only...See Area
Pages For Specifics
VLAN
Area 4 PLC 4.0
with GracePort Interface
Ctrl Area 4
Ctrl Area 4 Device Level
Ring
RIO – Area 4 2
VLAN
CLX – Area 4 0A CLX – Area 4 0B
RIO – Area 4 3
Area 4 PLC 4.1
FIBER
RIO – Area 4 1
Scale Weight (Qty 12)
x12
FIBER
x5
FT View SE HMI Client (Qty2)
VLAN x2
`
RIO – Area 4 4
FIBERArea 4 PLC 4.2
DLR STRATIX
HMI STRATIX
VLAN
AREA 5 PLC CABINET
Ctrl Area 5
Ctrl Area 5 Device Level
Ring
RIO – Area 5 2
VLAN
CLX – Area 5 0A CLX – Area 5 0B
MODBUS
RIO – Area 5 1
MODBUS
Ctrl Area 5 Drives (Qty 2)
Spang SCR – Power Control (Qty 7)
MODBUS x7
Spang SCR – Power Control (Qty 8)
MODBUS x8
SPANG Network Enclosure
MicroLogix 1100 ATS (Qty 2)
x2
FIBER
Scale Weight (Qty 2)
Power Logic Monitor (Qty 6)MODBUS x6
x2
FIBER VLAN
VLAN
MB STRATIX
DLR STRATIX
HMI STRATIX
DLR Representation
Is Symbolic
Only...See Area
Pages For Specifics
VLAN
Ctrl Area 1
Ctrl Area 1 Device Level
Ring
Drives (Qty 9)
RIO – Area 1 2
VLAN
CLX – Area 1 0A CLX – Area 1 0B
RIO – Area 1 3
Area 1 MCC
FIBER
MODBUS
RIO – Area 1 1
MODBUS
Drives (Qty 2)
FIBER
Spang SCR – Power Control (Qty 16)
MODBUS x16
Spang SCR – Power Control (Qty 16)
MODBUS x16
SPANG Network Enclosure
HMI STRATIX
MB STRATIX
DLR Representation
Is Symbolic
Only...See Area
Pages For Specifics
VLAN
Ctrl Area 2
Ctrl Area 2 Device Level
Ring
SLC 5/05 – Gas Safety A
SLC 5/05 – Gas Safety B
Drives (Qty 20)
MicroLogix 1100 ATS (Qty 6)
RIO – Area 2 1 RIO – Area 2 2
FIBER
RIO – Area 2 4
RIO – Area 2 4
Power Logic Monitor (Qty 8)
Generator Control Panel
Area 2 PLC 1.2
Area 2 PLC 1.1
with GracePort Interface
VLAN
CLX – Area 2 0A CLX – Area 2 0B
Gas Safety Panel
MODBUS
MODBUS
MODBUS x8
x6
Drives (Qty 4)
FIBER
VLAN
`
FT View SE HMI Client
HMI STRATIX
FN_DLRSTRX
MB STRATIX
DLR Representation
Is Symbolic
Only...See Area
Pages For Specifics
`
FT View SE HMI Client
`
FT View SE HMI Client
`
FT View SE HMI Client
DLR Representation
Is Symbolic
Only...See Area
Pages For Specifics
1200 I/O, 5 Areas, 8 Consoles, MES/Historian, 30 Drives, Virtualized
15. Paper Machine Phased Migration
2000 I/O, 3 Areas, 10 Consoles, PI Addressing, Virtualized
16. Glass Plant Paper Mill
I/O total 1385 2100
Remote I/O enclosures 0 21
PCU's 4 PCU, 8 MFP 4 PCU, 9 MFC
CLX Controllers 5 Redundant Pair 3
HMI Consoles 12 10
HMI Graphics 25 plus 15 custom popups 99 plus 40 popup faceplates
Interfaces
Resolver Interface Module, 20 30 +
ModbusTCP devices, 30+ PowerFlex
Drives (new), 50+ HART xmtrs/actuators PI, GE Drives, PLC5, ModBus
Historian x x
Drives PowerFlex, in new scope GE Serial Interface
Optimimzation x interface to VAX
PI scope New, FTHistorian yes, to be comverted to FTHistorian
Schedule
Strategy
System Price
$ changes
RoviSys first full Plant Pax Plant Pax look with custom CMs for Bailey
Custom faceplates & CMs Work with Bailey configs during phasing
Virtualized Servers Virtualized Servers
Client specify VM Rockwell design for high availability
simple, less expensive, 2 servers 3 servers, Vsphere selects Server for reliability
support not as convenient push button' backups
17. Glass Plant Paper Mill
I/O total 1385 2100
Remote I/O enclosures 0 21
PCU's 4 PCU, 8 MFP 4 PCU, 9 MFC
CLX Controllers 5 Redundant Pair 3
HMI Consoles 12 10
HMI Graphics 25 plus 15 custom popups 99 plus 40 popup faceplates
Interfaces
Resolver Interface Module, 20 30 +
ModbusTCP devices, 30+ PowerFlex
Drives (new), 50+ HART xmtrs/actuators PI, GE Drives, PLC5, ModBus
Historian x x
Drives PowerFlex, in new scope GE Serial Interface
Optimimzation x interface to VAX
PI scope New, FTHistorian yes, to be comverted to FTHistorian
Schedule install 12 mon after order 2 year plus cutover plan
Strategy Rip & Replace Phased Migration
System Price $1.4MM $1.9MM
$ changes $150K $350K
RoviSys first full Plant Pax Plant Pax look with custom CMs for Bailey
Custom faceplates & CMs Work with Bailey configs during phasing
Virtualized Servers Virtualized Servers
Client specify VM Rockwell design for high availability
simple, less expensive, 2 servers 3 servers, Vsphere selects Server for reliability
support not as convenient push button' backups
18. Summary
• Plan
• Audit
• Update Documentation
• Migration Plan and FEL Pricing
• Look for Payback
• Operations
• Maintenance & Support
• Long term operational benefits
• Understand what drives your company’s decisions
• Partner with someone who has seen it all
20. Who are we?...
The RoviSys Company
• Founded in 1989
• ~600 Employees
• Rockwell Automation Solution Partner
• Certified Member CSIA, Control and Information System Integrators Association
• Rockwell’s Bailey Migration Tools, cables, and OLDI cATM-BLY90
• Rockwell Cable Solutions to DCS I/O Terminations; Bailey, APACS, RS3, etc.
• Automation and Information Systems
21. Contact Information
• Dan Burger, P.E., C.E.M. – Business Development Market Manager
Dan.burger@rovisys.com
(330)936-1112
• James Riccardi, P.E. – Group Manager, California Projects
Riccardi@rovisys.com
(330)472-3034
